Home >Documents >BODAS Controller RC Series 30 - hydba.com©cnica... · RE 95204/07.2015, Bosch Rexroth AG BODAS...

BODAS Controller RC Series 30 - hydba.com©cnica... · RE 95204/07.2015, Bosch Rexroth AG BODAS...

Date post:20-Apr-2019
Category:
View:228 times
Download:2 times
Share this document with a friend
Transcript:

RE 95204/07.2015, Bosch Rexroth AG

Features High performance thanks to ultra-modern 32-TriCore

technology with 180 MHz Component of BODAS system for mobile applications Robust design meeting specifi cations for mobile

applications High electromagnetic compatibility (EMC) Inputs and outputs with fault detection Central deactivation of all outputs Pulse-width-modulated (PWM) solenoid currents for

minimum hysteresis Closed-loop control of solenoid currents, i.e.,

not dependent on voltage and temperature

Main components

Watchdog processor for program run monitoring Hardware-based RAM memory supervision CPU-internal Flash with ECC error-correcting code Three independent sensor power supplies Four independent CAN bus interfaces Two-channel stop function

For closed- and open-loop control of hydraulic components

BODAS Controller RC Series 30

RE 95204Edition: 07.2015Replaces: 02.2012

ContentsOrdering code 2Optional accessories 2Description 3Block circuit diagram 4Technical data 5Connection diagram 7Connection variants 10Overview of functions 11Dimensions 17Installation position 18Mating connector 19Safety information 21

RC28-14/30RC20-10/30RC12-10/30

Bosch Rexroth AG, RE 95204/07.2015

2 RC | BODAS Controller Ordering code

Ordering code

01 02 03

RC / 30

Type01 BODAS controller RC

Version02 1st number: number of proportional outputs

2nd number: number of switched outputs28-1420-1012-10

Series03 Series 3, index 0 30

Notes: The BODAS controllers are not functional without

software. In order to use the BODAS controllers, you also need:

BODAS standard software or application-specifi c software

If there is a sample label on the name plate, it is a prototype or sample, i.e., components not released for serial production. Possible sample labels are: SC: A SC: B SC: C SC: S (Software prototypes)

Optional accessories

BODAS-design softwareThe windows-based BODAS-design PC software (data sheet 95112) is used for programming the BODAS RC controllers. All graphical and textual programming lan-guages specifi ed according to IEC 61131-3 are available for the programming.

BODAS-service softwareThe windows-based BODAS-service PC software (data sheet 95086) is used for displaying functions, errors and system variables as well as for setting parameters via a PC.

C programming interface C-APIThe C-API (data sheet 95115) programming interface is used for programming the BODAS RC controllers in the C programming language. All required functions that are needed for the confi guration and the reading of the inputs, the control of the outputs, the use of the com-munication interfaces and the creation of the diagnos-tics information for BODAS-service are available to the user.Additionally, the user needs a C-compiler, with which the created program is translated into a machine code that is readable for the BODAS controller.

BODAS MA6 measuring adapterThe BODAS MA6 measuring adapter (data sheet 95090) facilitates measuring all electrical signals at the inputs, outputs and interfaces of the BODAS controller. For testing purposes, it is connected in series between the control unit and the vehicle or device wiring.

BODAS TB3 test box(2 pieces) and adapter kit (1 piece)The BODAS TB3 test box (data sheet 95092) is used for simulation of vehicle and device functions for develop-ment and testing purposes with BODAS controllers. The BODAS TB3 test boxes are connected to the control unit via the adapter TAK4/10 .

All products mentioned here are available from Bosch Rexroth. Further information can be found on the internet at: www.boschrexroth.com/mobile-electronics

RE 95204/07.2015, Bosch Rexroth AG

BODAS Controller | RC Description

3

Description

These BODAS controllers RC are designed as universal central control units for complex mobile working machines. Thanks to the ultra-modern 32-bit TriCore technology, a clock frequency of 180 MHz and parallel processing, these control units push into completely new performance dimen-sions that were previously reserved for larger PLC systems. The fi elds of application extend from the programmable control of proportional solenoids and additional switching functions to travel drives and transmission control as well as coordination of highly complex control circuits in mobile working machines. With 75 input channels, up to 42 output stages, four voltage outputs (25% * Vbat to 75% * Vbat), an additional analog output (4 to 20 mA) as well as four CAN buses for communication in the vehicle, these control units provide a high-performance platform for all functions of mobile working machines.

Internally, the series 30 BODAS RC controllers contain a high performance 32-bit TriCore microprocessor and all input and output circuits. Analog voltages in the range from 0 to 10 V and 0 to 32 V, currents from 0 to 20 mA, frequen-cies from 0 to 10 kHz and switching information are pro-cessed as input signals. In addition, these control units off er special inputs for intelligent Bosch Rexroth sensors, such as the DSM1-10 speed sensor with integrated diag-nostics function or resistor inputs from 10 to 2000 , for example for the direct connection of temperature sensors. The inputs are protected against overvoltage and electrical interference. The voltage inputs can be monitored to detect any cable breaks or short circuits. The current-controlled proportional solenoid outputs are pulse-width-modulated (PWM) and are compensated for fl uctuating temperature and voltage for high accuracy and minimum hysteresis. They are optimally harmonized with the electrical proportional control of the axial piston units and valves of BoschRexroth. The switching outputs are designed for direct switching of relays and switching solenoids. Moreover, the outputs have integrated voltage and current monitoring.

CAN-bus interfaces are included in all BODAS RC control-lers for exchanging data with other bus users or electronic systems (e.g. RC, joystick, diesel engine injection, display). Each of the four independent CAN bus interfaces can be operated using diff erent protocols. Communication with the BODAS-design and BODAS-service software is likewise done via CAN bus and is based on the Standard Key Word Protocol 2000 (KWP 2000).

Simple and fl exible programming of the BODAS controller according to the industry standard IEC 61131-3, which enables a very convenient and rapid introduction to the programming of the controller, is possible with the BODAS-design software. Comprehensive and complex applications can be conveniently developed and clearly represented with BODAS-design.

An application interface in the form of a C-API interface is available for the development of the full performance capa-bility of these BODAS controllers when the C programming language is used. By using the C-API, the software devel-oper can concentrate on the important functions of his machine without having to become immersed in the details of the TriCore technology.

With the BODAS-service software, the programs can be quickly and easily downloaded to the control unit via the Flash module. Extensive service functions, such as diagnos-tics, parameter setting or display of process variables, are available via the graphical Windows interface of BODAS-ser-vice. This allows simple parameter setting and diagnostics in order to place the machine in service quickly and safely.

The BODAS RC controllers were developed specifi cally for use in mobile working machines and satisfy corresponding protection requirements regarding ambient temperatures, water and dust ingression, shock and vibration as well as electromagnetic compatibility (EMC).

BODAS RC controllers and corresponding software in combination with pumps, motors, valves, sensors, input devices and actuators from Bosch Rexroth make for com-plete system solutions.

Safety-relevant project planning instructions (95451-01-B for EN ISO 13849 and 95452-01-B for ISO 25119) have to be observed for the planning and implementation of safety functions and the two-channel stop function. These are available from Bosch Rexroth on request.

Bosch Rexroth AG, RE 95204/07.2015

4 RC | BODAS Controller Block circuit diagram

Block circuit diagram

High-side proportional solenoid outputs2.5 A

3 Sensor supply 5 V

2 Sensor supply 10 V

1 Sensor supply 5 V

1 Analog output 4 to 20 mA

1...4 CAN bus interfaces

Central safety cut-off

Power outputs

PWM output stage

Interface drivers

Switching output stage

Voltage 10 V

Voltage5 V

Current4 to 20 mA

Measuring

status

Measuring

Measuring

Measuring

PWM output stage

Voltage 25%...75% x Vbat

Power supply

TriCore TC1797 32-bit microcontroller

pFlash4 MB

RAM104 kByte

Output control unit

Interface controller

Power supply

Watchdog

External inhibit1)

SPI bus

C DSP RISC C

Digital input

dFlash64 kByte

HW RAMcomparator

3separate

ADconverters

12 bit

32 kByteextern

EEPROM1 MByteexternRAM

Voltage5 V

External inhibit1)

Power supply output stages

Ignition switch (Terminal 15)

Frequency inputs

Voltage inputs

Current inputs

Temperature inputs

Switching inputs

Power supply with intelligent

watchdog

Activation pulse

Frequencyinductive

Frequencyactive

Current0 to 20 mA

Temperature(resistance)

Switch

Voltage0 to 10 V

Voltage0 to 32 V

FrequencyDSM

Deactivation channel2)

SW INH

Electronics power supply

Door contact (Wake)

Switch / voltage

0 to 10 V

9...10

1...2

6...8

2...10

1...5

3...9

1...10

1...4

1...32

1

Switching inputs

RC28-14/30 RC20-10/30 RC12-10/30

1...18 1...10 1...6

1...10 1...10 1...6

Low-side proportional solenoid outputs3.0 A / 4.0 A

1...14 1...10 1...10

Switching outputs2.2 A / 3.5 A

1...4 Analog outputs25%...75% Vbat

1) Input that is independent of the microcontroller, for the central enabling/deactivation of the power outputs.2) Input for the central enabling/deactivation of the power outputs.

Abbreviations

C microcontroller

DSP digital signal processor

RISC reduced instruction set computer

Footnotes for page 51) Exception: GND, GND sensor, constant voltage sources and tem-

perature inputs to battery.2) Max. total current per group: 5 A 3) Sensor voltage inputs are raised when there is a short circuit to

battery. A correct reading of sensor signals is no longer ensured. Connected sensors may be damaged.

4) Line protection. The wiring has to be rated according to the fuse protection.

5) Some functions do not comply fully with the respective specifi ca-tion at supply voltage < 11 V. See also overview of functions.

RE 95204/07.2015, Bosch Rexroth AG

BODAS Controller | RC Technical data

5

Technical data

Controllers RC 28-14 20-10 12-10

Nominal voltage 12 and 24 V Residual ripple (DIN 40839, part 1) max. 2 V Supply voltage, permissible range 8 to 32 V ()5)

Current consumptionstandby, in the 12 V vehicle electrical system 380 mA standby, in the 24 V vehicle electrical system 290 mA loaded, in the 12 V vehicle electrical system max. 40 A loaded, in the 24 V vehicle electrical system max. 40 A

Fusesinternal: external: in the supply path4) 5 A (electronics), maximum 35 A (power outputs)

Controllers enabling pin Terminal 15 / Wake Constant voltage sources3)

e.g. for setpoint potentiometer 150 mA 5 V 150 mV 250 mA 5 V 250 mV 1000 mA 10 V 500 mV

Digital inputs 9

Digital voltage inputs, diagnostics capable 32Analog voltage inputs, pulldown 0 to 10 V 7

0 to 32 V 2Analog current inputs, diagnostics capable 0 to 20 mA 10Resistor inputs

e.g. for temperature sensors resistance measuring range 10 to 2000 4Frequency inputs total 10

DSM 0 to 9 kHzLevel: 7 mA/14 mA

5

Inductive sensors 0 to 10 kHz, Level: > 1 VRMS 2Active sensors 500 Hz to 10 kHz

level low: < 1 Vlevel high: > 4 V

3

Analog signal outputs total 5for 200 load (ohmic resistance)for 150 load (ohmic resistance)

4 to 20 mA0 V (off ), 0.1 to 5.0 V

1

for 12 k load (ohmic resistance) 0 V (off ), 0% * Vbat to 90% * Vbat (typically 25% * Vbat to 75% * Vbat)

4

Proportional solenoid outputs (PWM) total 28 20 12High side current range 0 to 2.5 A 18 10 6Pulsation frequency 0; 50 to 250 HzLow side current range 0 to 3.0 A

0 to 4.0 A82

82

42

Pulsation frequency 0; 50 to 250 Hz and 1000 HzDigital output stages total 14 10 10

High side current range max. 2.2 A 10 6 6High side current range max. 3.5 A2) 4 4 4

Interfaces 4CAN 2.0 B, ISO 11898

Fault detection in the event of cable break and short circuit Analog inputs Proportional solenoid outputs Switching solenoid outputs

Short circuit resistance when energizedto supply voltage and ground for all inputs and outputs1) 3) ()

See page 4 for footnotes

Bosch Rexroth AG, RE 95204/07.2015

6 RC | BODAS Controller Block circuit diagram

Controllers RC 28-14 20-10 12-10

Reverse polarity protection1)

Power supply/battery

Microcontroller SAK-TC1797

Clock frequency MHz 180

Memory capacities

RAM MByte 1

Flash EPROM MByte 4

EEPROM kByte 32

Software installationDownload to fl ash memory

Electromagnetic compatibility3)

Spurious interference (ISO 11452-2) 200 VRMS/m

Spurious interference (ISO 11452-5) 100 VRMS/m

Electrostatic discharge ESD (according to ISO 10605)

Out of service 8 kV

In service 15 kV

Max. power dissipation

Electronics W at 32 V 8.5

Output stages W at 32 V 60

Operating temperature, housingwith mounting point on cooling surface

-40 C to +85 C (-40 C to +185 F)

Storage temperature, housing Maximum permissible housing temperature in the short-term passive:-40 C to +105 C (-40 C to +221 F)

Vibration resistance

Broadband noise vibration(ISO 16750-3)

34 m/s2, 10 to 1000 Hz,32 h per axis10 Hz: 18 (m/s2)2/Hz20 Hz: 36 (m/s2)2/Hz30 Hz: 36 (m/s2)2/Hz180 Hz: 1 (m/s2)2/Hz2000 Hz: 1 (m/s2)2/Hz

Shock resistance a = 400 m/s2; t = 6 msper spatial axis x, y, z and in each direction (pos./neg.)Transport shock

(IEC 60068-2-27)

Moisture resistance(IEC 60068-2-30Db; variant 2)

95% (25 C to +55 C)

Salt spray resistance(IEC 60068-2-52, test Kb)

4x 2 h salt spray (5% NaCl) 22 h at 40 C/93% rF constant environment72 h at storage room temperature

IP rating (DIN EN 60529)2) with assembled mating connector IP65

Housing material Cover:Base:

Diecast aluminumDeep-drawing aluminum

Weight approx. kg 1.0 kg

Outer dimensions Length (in mm) 204.5

Width (in mm) 203

Height (in mm) 40.5

Mating connector 96-pin 1

58-pin 1

1) The external fuse can serve as reverse polarity protection.2) While following installation instructions.

3) Up to 500 kBaud when using the CAN interfaces.

RE 95204/07.2015, Bosch Rexroth AG

BODAS Controller | RC Connection diagram

7

31

+

+

+

+

+

+

+

+

+

+

B

A

B

B

A

A

A

A

A

A

B

A

A

B

A

A

A

B

A

A

B

A

A

A

B

A

A

B

B

A

A

A

A

A

A

A

IN_71

IN_72

IN_73

IN_74

IN_75

IN_68

IN_69

IN_70

IN_66

IN_67

110

113

112

111

109

108

133

132

213

208

250

236

209

147

223

134

135

137

136

210

222

238

252

157

148

159

158

214

211

144

143

224

142

235

247

234

225

212

248

237

239

251

+24 V+12 V/

30

15)VP_16)WAKE230

233220207202

246122123124

203201

258245

204205206

2401530

1 A

3 A

35 A

5 A

7)

3)

32

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

22

23

24

25

26

27

28

29

30

31

21

IN_1

IN_2

IN_3

IN_4

IN_5

IN_6

IN_7

IN_8

IN_9

IN_10

IN_11

IN_12

IN_13

IN_14

IN_15

IN_16

IN_17

IN_18

IN_19

IN_20

IN_21

IN_22

IN_23

IN_24

IN_25

IN_26

IN_27

IN_28

IN_31

IN_32

IN_30

IN_29

0 V/+5 V 13)

0 V/+5 V 13)

OUT_2

OUT_1

OUT_4

OUT_3

OUT_6

OUT_5

OUT_8

OUT_7

OUT_10

OUT_9

OUT_12

OUT_11

OUT_14

OUT_13

OUT_16

OUT_15

OUT_45

OUT_46

OUT_41

OUT_42

OUT_43

OUT_44

OUT_37

OUT_38

OUT_39

OUT_40

OUT_18

OUT_17

10

6

7

8

9

2

1

3

4

5

Ind

Aktiv

Aktiv

Aktiv

Ind

DSM

DSM

DSM

DSM

DSM

1 4.0 A

2 3.0 A

3 3.0 A

4 3.0 A

5 4.0 A

6 3.0 A

7 3.0 A

8 3.0 A

9 3.0 A

10 3.0 A

2 2.5 A

3 2.5 A

4 2.5 A

5 2.5 A

6 2.5 A

7 2.5 A

8 2.5 A

9 2.5 A

10 2.5 A

11 2.5 A

12 2.5 A

13 2.5 A

14 2.5 A

15 2.5 A

16 2.5 A

17 2.5 A

18 2.5 A

2)

2)

2)

2)

2)

2)

2)

2)

2)

2)

2)

2)

2)

2)

2)

2)

2)

2)1 2.5 A

188

187

179

180

181

182

183

184

185

186

177

153

178

154

175

151

176

152

173

149

174

150

131

130

101

126

129

125

1)

VSS_2

GND

20)

20)

20)

20)

20)

20)

20)

20)

20)

20)

high / low active

Proportional output

Optional voltage circuit breaker

Ignition switch

Switch-on signal

Switch digital inputshigh / low active

Connection diagram part 2 see page 8

See

next

pag

e fo

r co

nnec

tion

to p

in 1

46

Freq

uenc

y in

puts

Switc

hing

inpu

ts

Speed sensor

Volta

ge in

puts

Proportional output

Proportional output

Proportional output

Proportional output

Proportional output

Proportional output

Proportional output

Proportional output

Proportional output

Proportional solenoids

Proportional solenoids

Proportional outputs

Proportional outputs

Proportional outputs

Proportional outputs

Proportional outputs

Proportional outputs

Proportional outputs

Proportional outputs

Proportional outputs

Electronics voltage supply17)

Power output voltage supply

0 V ground

18)

18)

19)

Connection diagram

RC28-14/30 RC20-10/30 RC12-10/30

Bosch Rexroth AG, RE 95204/07.2015

8 RC | BODAS Controller Connection diagram

RC28-14/30 RC20-10/30 RC12-10/30

Not assigned

Vbat

A

A

A

A

B

A

A

B

B

C

B

B

B

B

A

B

B

A

A

A

A

A

A

A

CC

C

C

CC

C

C

C

4 ... 20 mA

3.5 A

3.5 A

25...75 % Ubat

25...75 % Ubat

2.2 A

2.2 A

25...75 % Ubat

25...75 % Ubat

2.2 A

2.2 A

2.2 A

2.2 A

3.5 A

3.5 A

2.2 A

2.2 A

2.2 A

2.2 A

4...20 mA

CAN H1CAN L1

CAN H3CAN L3

CAN H2CAN L2

CAN H4CAN L4

8)

8)

8)

8)

8)

8)

8)

8)

8)

8)

IN_52

IN_53

IN_54

IN_55

IN_56

IN_57

IN_58

IN_60

IN_61

IN_59

10)

10)

10)

165

170

169

167

227

171

229

218

168

138

VP_1

VP_2

15)

VP_115)

15)

9)

9)

9)

9)

IN_62

IN_63

IN_64

IN_65

145

116

117

118

121

5)

5)

5)

INH

IN_42

IN_43

IN_44

IN_45

IN_46

IN_47

IN_50

IN_51

IN_48

IN_49

VSS_3

VSS_2

VSS_1

IN_40

IN_41

IN_38

IN_34

IN_33

IN_39

IN_35

IN_37

IN_36

228

192

191

249

196

172

156

155

140

115

114

219

255

146

232

141

164

166

139

231

217

226

120

119

INHSW-INH

12)

14)

6,5 V

Ubat

128

103

107

106

190

189

194

193

243

241

242

256

244

257

8)

127

102

104

2)

2)

2)

2)

2)

2)

2)

2)

2)

2)

2)

2)

2)

2)

2)

2)

2)

2)

105

195

221

160161

162163

254253

215216

OUT_19

OUT_20

OUT_35

OUT_36

OUT_21

OUT_22

OUT_34

OUT_33

OUT_23

OUT_24

OUT_25

OUT_26

OUT_27

OUT_28

OUT_29

OUT_30

OUT_31

OUT_32

OUT_47

1)

1

2

1

3

4

2

3

4

5

6

7

8

9

10

11

12

13

14

1

2

3

4

1

2

3

4

5

6

7

8

9

1

2

3

4

5

1

6

7

8

9

10

1

2

3

4

5

6

7

8

9

10

1

2

3

4

16)

GND_S1

GND_S2

Switc

hing

inpu

ts

Constant voltage source 5 V/150 mA

Constant voltage source 10 V/1000 mA

Sensor ground 5 A

3.3 V constant voltage

Tem

pera

ture

in

puts

Current source0 to 20 mAor alternative voltage source0 to 10 V

Active sensors/potentiometer0 to 10 Vswitch

Active sensors/potentiometer0 to 32 Vswitches

Switching outputs

Proportional outputs

Cur

rent

inpu

ts/v

olta

ge in

puts

5 A sensor ground

Volta

ge in

puts

Proportional outputs

Constant voltage source 5 V/250 mA

Switching outputs

Switching outputs

Switching outputs

Switching outputs

Switching outputs

Switching outputs

Stop switch

Switch digital inputs low active

Temperature inputsPTC 100010 bis 2000

See

page

1 fo

r co

nnec

tion

Connection diagram part 1 see page 7

CAN bus4) interface

CAN bus4) 16) interface

CAN bus4) 16) interface

CAN bus4) 16) interface

Pilot signal outputs

Analog signal output

Vbat

Vbat

Vbat

Vbat

RE 95204/07.2015, Bosch Rexroth AG

BODAS Controller | RC Connection diagram

9

1) Short, low-resistance connection from a housing screw to the vehi-cle ground.

2) Independent ground connection to battery (via chassis possible). 3) Separate fuse required for switches and sensors. Sensor supply

application specifi c.4) CAN bus: 120 termination resistor and twisted pair wire required. 5) 5 V/10 V outputs can also be used as sensor supply.6) Temporary wake up of the control unit when a signal > 8 V is ap-

plied for more than 1 sec. 7) Note max. current consumption with simultaneous actuation of

proportional solenoids and switching outputs.8) Separate ground connection for current source to the battery, con-

trol unit GND possible9) Can be used as switching inputs if externally switched to GND. 10) For use as voltage inputs (0 to 10 V), the internal ohmic resistance

can be switched by the software in groups for these inputs.Groups: inputs 1 to 2, inputs 3 to 6, inputs 7 to 10.

11) Outputs arranged in groups with 2 output stages each. Maximum permissible output current per group: 5 A

12) Primary deactivation channel for proportional and switch outputs:enabling with level > 4.5 V, deactivation with level < 1 V,cable break leads to deactivation.

13) Input groups may be switched to pull down or pull up in software. 14) Secondary deactivation channel for proportional and switch outputs:

enabling with level < 0.7 V, deactivation with level > 2 V, cable break leads to deactivation.

15) Supply can be switched by the software.16) Shuts off on response from watchdog.

Temporarily interrupted for diagnostic purposes when turning on the main switch for the fi rst time.

17) If disabled during operation, data will not be saved to the non-vola-tile memory and there will be no after-run.

18) A, B and C indicate diff erent A/D converters which may be selected for redundancy reasons.

19) Terminal 31 (supply ground) and sensor ground are bridged at a star point in the control unit and connected to the housing.

20) Loads on low-side outputs should be supplied by high-side outputs so that they can also be disabled in the event of a short circuit to ground. See Safety outputs in the API manual. If this is not possi-ble, the power must be routed through a relay switched via Termi-nal 15. In this case, the lines must be equipped with fuses. Con-necting directly to Terminal 30 is not permitted.

Footnotes for pages 7 and 8

Bosch Rexroth AG, RE 95204/07.2015

10 RC | BODAS Controller Connection variants

Connection variants

Monitored potentiometer 2.5 to 5 k

Fault monitoring of the potentiometer Internal measurements of the sensor supply voltage (5 V) Connection of the potentiometer to a current input, via

which the current of the potentiometer is checked. Checking the loop voltage. It must be within a valid

range (software).

Switching input with fault detection

Fault monitoring of the switching inputs Switching of the input voltage between 10 V and 5 V Reading the switching level and checking the valid range

(software)

232

219

Sens

or

supp

ly 1

0 V

Sens

or

supp

ly 5

VVo

ltage

inpu

t

Sens

or s

uppl

yVo

ltage

inpu

tC

urre

nt in

put

RE 95204/07.2015, Bosch Rexroth AG

BODAS Controller | RC Overview of functions

11

Overview of functions

Pin Description Main function Alternative functions

250, 236, 209, 147, 223, 148, 159, 158, 214, 157, 252, 238, 222, 210, 136, 137, 135, 134, 211, 144, 224, 143, 142, 235

to ADC

Pin

GNDGND GND

6.4

k

VSS_2(10 V)

15.0

k

Digital inputIN_1 to IN_24

15 k pull-up resistance to VSS_2 sensor supply1) and 5.6 k pull-down resis-tance to ground

Digital inputSwitching threshold confi gurable via software (max. 10 V)Externally switchable to GND, VSS_x or Vbat.

If Vbat = 24 V then max. 10 of these inputs may be switched to 24 V simultaneously.

Analog voltage inputMeasuring range: 0 to 10 VResolution: 12 bit (2.7 mV/bit)Input resistanceDC to GND: 5.6 k DC to VSS_2: 15.0 k Filter frequency limit: 330 Hz

Limited diagnostics of cable breakage due to fi xed pull-up and pull-down resistance

247, 234, 225, 212248, 237, 239, 251

from CPU

to ADC

Pin

GND

GND

GND

21.5

k

5 VDC

Digital input

Pull-up/pull-down resis-tance can be switched be-tween 5V/ground in two groups

IN_25 to IN_28

IN_29 to IN_32

Digital inputSwitching threshold confi gurable via software (max. 10 V)Externally switchable to GND, VSS_x or Vbat.

Open terminal voltage:Pull-up: 3.5 V Pull-down: 0 V (default)

Analog voltage inputInput resistance with pull-up confi guration:21 k to 5 V and 50 k to GNDInput resistance with pull-down confi guration:15 k to GND Filter frequency limit: 330 Hz

164, 166, 231, 217, 226, 139, 141

to ADC

Pin

GND GNDGND

21.5

k

Analog voltage inputIN_33 to IN_39

Analog voltage inputMeasuring range: 0 to 10 VResolution: 12 bit (2.71 mV/bit)Input resistanceDC to GND: 15 kFilter frequency limit: 330 Hz

Digital input active highEvaluation options:

Switching threshold confi gurable via soft-ware (max. 10 V)

Externally switchable to VSS_x

119, 120

to ADC

Pin

GND GNDGND

21.5

k

Analog voltage inputIN_40 to IN_41

Analog voltage inputMeasuring range: 0 to 32 VResolution: 12 bit (8.8 mV/bit)Input resistanceDC to GND: 15 kFilter frequency limit: 800 Hz

Digital input active highEvaluation options:Switching threshold confi gurable via soft-ware (max. 32 V)

Externally switchable to VSS_x or Vbat

114

Pin

GND

21.5

k

6.5 V

toLogic

Digital inputIN_42 (SW INH)

21.5 k pull-up resistor to 6.5 V

Secondary inhibit inputActivation of output stages:Level low < 0.7 V(switch to GND with low resistance)Deactivation of output stages:Level high > 2 V, Vbat(switch open)

Cable break leads to the deactiva-tion of all output stages.

Digital input active lowEvaluation options:Digital switching thresholdsLevel low < 0.7 V(switch to GND with low resistance)Level high > 2 V (switch open)

Filter frequency limit: 100 Hz

1) When Vbat 11 V, VSS_2 = 10 V; when Vbat

Bosch Rexroth AG, RE 95204/07.2015

12 RC | BODAS Controller Connection variants

Pin Description Main function Alternative functions

115, 140, 155, 156, 172, 191, 192, 196, 249

toLogic

Pin

GND

21.5

k

6.5 V

Digital inputIN_43 to IN_51

21.5 k pull-up resistor to 6.5 V

Digital input active lowEvaluation options:

Digital switching thresholdsLevel low < 0.7 V(switch to GND with low resistance)Level high > 2 V (switch open)

Filter frequency limit: 100 Hz

213, 208

CPUconnec-tion

Pin

GND

VSS_2

GND

6.81

k

ADC

Active frequency inputIN_66 to IN_67

6.8 k pull-up resistor to VSS_21) and 24 k pull-down resistor to ground

Frequency input for Type NPN active sensors

Frequency evaluation of active speed sensors that switch to ground.

Frequency evaluation up to 10 kHz

Phase measuring between IN_66(Pin 213) and IN_67 (Pin 208)

Short circuit current up to 1.4 mA

Low active digital inputEvaluation options:

Switching threshold confi gurable via soft-ware (max. 5 V)Digital switching thresholdsLevel low < 1 V(switch to GND with low resistance)Level high > 4 V (switch open)Open terminal voltage: > 6 V

108

CPUconnec-tion

Pin

VSS_2(10 V)

6.81

k

Active frequency inputIN_68

6.8 k pull-up resistor to VSS_21) and 24 k pull-down resistor to ground

Frequency input for Type NPN active sensors

Frequency evaluation of active speed sensors that switch to ground.

Frequency evaluation up to 10 kHz

Short circuit current up to 1.4 mA

133, 132

CPUconnec-tion

Pin

GND GND

GND

4.64 k

ADC

Inductive frequency inputIN_69 to IN_70

44 k pull-down resis-tance to ground

Frequency input for Type PNP and NPN inductiveand active sensorsFrequency evaluation: 500 Hz to 10 kHz

Min. required signal amplitude: 1 VRMS (sine wave)Phase measuring betweenIN_69 (Pin 133) andIN_70 (Pin 132)

High active digital inputEvaluation options:

Switching threshold confi gurable via soft-ware (max. 32 V)(switch to Vbat with low resistance)Open terminal voltage: < 1 V

Analog voltage inputMeasuring range: 0 to 32 VResolution: 12 bit (7.6 mV/bit)

1) When Vbat 11 V, VSS_2 = 10 V; when Vbat

RE 95204/07.2015, Bosch Rexroth AG

BODAS Controller | RC Connection variants

13

Pin Description Main function Alternative functions

112, 113, 110, 111, 109

CPUconnec-tion

Pin

VSS_2

243

DSM frequency inputIN_71 to IN_75

This input has an internal pull-up resistance of 243 to VSS_2 (10 V).

Frequency input for Rexroth DSM sensors

Frequency evaluation up to 9 kHzEvaluation of additional information, such as direction of rotation and fault monitoring.

Frequency input for Type NPNactive sensors

Frequency evaluation of active speed sensors that switch to ground.

Level low < 5 V (7 mA)Level high > 9 V (13 mA)

Phase measuring between IN_71(Pin 112) and IN_72 (Pin 113)Phase measuring between IN_73(Pin 110) and IN_74 (Pin 111)

Attention: Short circuit current to ground up to 40 mA.

Digital input switching to GND

Evaluation options:- Digital current threshold10 mA 3 mA

138, 168 218, 229, 171, 227 167, 169, 170, 165

from CPU

to ADC

Pin

GND

GND

GND

495

21.5

k

Analog current inputwith switchable internal ohmic resistanceIN_52 to IN_61

Switchable in three groups between analog current and voltage input

IN_52 and IN_53IN_54 to IN_57IN_58 to IN_61

Analog current measuring inputMeasuring range: 0 to 20 mAInternal ohmic resistance: 490 Resolution: 12 bit (5.5 A/bit)

Filter frequency limit: 330 Hz

In 12 V applications two current inputs may be connected in parallel to halve the internal ohmic resistance.

Analog voltage inputMeasuring range: 0 to 10 VResolution: 12 bit (2.71 mV/bit)Input resistanceDC to GND: 12.38 kFilter frequency limit: 330 Hz

Digital input active high

Evaluation options:Switching threshold confi gurable via software (max. 10 V)Open terminal voltage: < 1 V

121, 116, 117, 118

to ADC

Pin

GND

3.3 VDC

GND

1.0

k

Temperature input IN_62 to IN_65

1 k pull-up resistor to 3.3 V and 150 k pull-down resistor to ground

Not short circuit-proof to battery.

Temperature measurement via resis-tance measurement of connected tem-perature sensors

Evaluation of passive temperature sen-sors with PTC measuring shunts from 10 to 2000 .

Supported Bosch Rexroth sensors:TSF (RD 95180)TSA (RD 95181)

Digital input active lowEvaluation options: Switching threshold confi gurable via software (max. 3.3 V)(switch to GND with low resistance or switch open)Open terminal voltage: > 3 V

Analog voltage inputMeasuring range: 0 to 3 VResolution: 12 bit (0.8 mV/bit)Filter frequency limit: 230 Hz

Bosch Rexroth AG, RE 95204/07.2015

14 RC | BODAS Controller Connection variants

Pin Description Main function Alternative functions

153, 177, 154, 178, 151, 175, 152, 176, 149, 173, 150, 174, 130, 131, 126, 101, 125, 129

Pin

GNDGND

22 k

Freewheeling

diodePWR_ON

HS switch

GND

R050

Current measurement to ADC

from CPU

from main switch(battery voltage)

High-side switch

from main switch(battery voltage)

Free-wheeling diode

Statusto CPU

PWM output stage OUT_1 to OUT_18

PWM output stage High-side switchClock frequency adjustable via software

Integrated free-wheeling diode for switching of inductive loadsMax. current: 2.5 ADuty factor: 0 to 100%Power supply centrally switchable via VP_1

Switching output stage with diagnostics duty cycle: 100%

184, 185, 186, 180, 181, 182, 188, 187

Pin

GNDGND

Freewheeling

diode

PWR_ON

LS switch

GND

R068

Battery voltage

from CPU

Low-side switch

Current measurement to ADC

Free-wheeling diode

Statusto CPU

PWM output stageOUT_38 to OUT_40andOUT_42 to OUT_46

PWM output stageLow-side switchClock frequency confi gurable via software

Integrated free-wheeling diode for switching of inductive loads

Max. current: 3.0 ADuty factor: 0 to 100%

Switching output stage with diagnosticsDuty cycle: 100%

183, 179

Pin

GNDGND

Freewheeling

diode

PWR_ON

LS switch

GND

R050

Battery voltage

from CPU

Low-side switch

Current measurement to ADC

Free-wheeling diode

Statusto CPU

PWM output stageOUT_37 and OUT_41

PWM output stageLow-side switchClock frequency adjustable via software

Integrated free-wheeling diode for switching of inductive loads

Max. current: 4.0 ADuty factor: 0 to 100%

Maximum current depends on duty fac-tor and load.

Switching output stage with diagnosticsDuty cycle: 100%

105, 104, 127, 102

from CPU

Voltage measure-mentto ADC

Pin

Ubat

GND

3.48 k

GNDGND

GND

Analog voltage output OUT_33 to OUT_36

PWM control voltage Output voltage: 0% x Vbat to 90% x Vbat (typically 25% x Vbat to 75% x Vbat)400 to 5000 Hz

OUT_33 to OUT_36:Power supply centrally switchable via VP_1

Battery voltage

RE 95204/07.2015, Bosch Rexroth AG

BODAS Controller | RC Connection variants

15

Pin Description Main function Alternative functions

107, 106, 190, 189, 194, 193, 242, 256, 244, 257

Pin

GNDGND

22 k

Freewheeling

diodePWR_ON

HS switch

GND

Free-wheeling diode

Statusto CPU

from CPU

from main switch(battery voltage)

High-side switch

from main switch(battery voltage)

Currentsensingto ADC

Switching output stage with current sensing OUT_21 to OUT_26 andOUT_29 to OUT_32

High-side switchswitching output stage1)

Max. current 2.2 A

Integrated free-wheeling diode for switching of inductive loads

Power supply centrally switchable via VP_2

128, 103, 243, 241

Pin

GNDGND

22 k

Freewheeling

diodePWR_ON

HS switch

GND

Free-wheeling diode

Statusto CPU

from CPU

from main switch(battery voltage)

High-side switch

from main switch(battery voltage)

Currentsensingto ADC

Switching output stage with current sensing OUT_19 to OUT_20andOUT_27 to OUT_28

High-side switchswitching output stage1)

Max. current 3.5 A

Integrated free-wheeling diode for switching of inductive loads

OUT_19 to OUT_20: switchable via VP_1 OUT_27 to OUT_28: switchable via VP_2

221

Pin

GND

VSS_2

56

GND

Reverse battery protection

diode

Current sensingto ADC

Voltage sensingto ADC

from CPU Reverse polarity protection

Analog signal outputOUT_47

Analog current output Output signal 4...20 mAwith 200 external ohmic resistance Output powered via VSS_2

Analog voltage outputOutput signal 0 V (off ), 0.1 to 5.0 V150 external ohmic resistance to ground required

219 Sensor supply VSS_1

Sensor supplyOutput voltage 5.0 VAccuracy 0.15 VLoad capacity 150 mA

232 Sensor supply VSS_2

Sensor supply, deactivatableOutput voltage 10.0 V2)

but not more than Vbat -1 VAccuracy 0.50 VLoad capacity: 1000 mA

255 Sensor supply VSS_3

Sensor supply, deactivatableOutput voltage 5.0 VAccuracy 0.25 VLoad capacity 250 mA

1) Software confi guration as proportional output with 100% duty cycle required.

2) When Vbat 11 V, VSS_2 = 10 V; when Vbat

Bosch Rexroth AG, RE 95204/07.2015

16 RC | BODAS Controller Connection variants

Pin Description Main function Alternative functions

228

Pin

GND GND

Shutoff VP_1 and VP_2

CPU connection

External inhibitINH

Primary inhibit inputActivation of the output stages: Level > 4.5 V, VbatDeactivation of output stages: Level < 1 V Cable break leads to the deactivation of all output stages.Input resistanceDC to GND: 34 k

230

Pin

GNDGND GND

Enable power supply

Door contact WAKEEnables temporary power up of the con-trol unit

Digital inputSwitch on control unit Level > 8 V, Vbat Input resistanceDC to GND: 18.5 k

240

Pin

GND

Enable power supply

KL15 ignition switchPower on signal for the control unit

Digital inputController activation Level > 8 V, Vbat Input resistanceDC to GND: 10 k

215, 216

Pin

1.21

k1.

21 k

GNDPin

CANhigh

CANlow

TxD

RxD

from CPUto CPU

CAN interfaceCAN1_H, CAN1_L

CAN interfaceCAN 2.0 B, factory setting 250kBaud, standard diagnostics interface up to 1 Mbaud, termination resistor in cable harness required

253, 254Pin

1.21

k1.

21 k

GNDPin

CANhigh

CANlow

TxD

RxD

from CPUto CPU

CAN interfaceCAN2_H, CAN2_L

CAN interfaceCAN 2.0 B, up to 1 Mbaud, termination resistor in cable harness required

163, 162

Pin

1.21

k1.

21 k

GNDPin

CANhigh

CANlow

TxD

RxD

from CPUto CPU

CAN interfaceCAN3_H, CAN3_L

CAN interfaceCAN 2.0 B, up to 1 Mbaud, termination resistor in cable harness required

161, 160

Pin

1.21

k1.

21 k

GNDPin

CANhigh

CANlow

TxD

RxD

from CPUto CPU

CAN interfaceCAN4_H, CAN4_L

CAN interfaceCAN 2.0 B, up to 1 Mbaud, termination resistor in cable harness required

RE 95204/07.2015, Bosch Rexroth AG

BODAS Controller | RC Dimensions

17

Dimensions

42 37.9

13.5

1

146

159.

5

241.761.4

218.

8

106.9287.2

180.32.570.3

84

23.5

4 18

11

188

1

203

1

24.21 591204.5

99.61

132.1

24.4

0.

4

a b

dc

Long-side side view

Plan view

Display without scale, dimensions in mm

View from below

Side view of connector side with pulled connector

Fixing:

The BODAS controller must be fi xed at 4

positions (a, b, c and d).

Tightening torque MA = 8 2 Nm for mount-

ing the BODAScontrol unit with M6 screws.

Tightening torque applies for fi tting without

washer. The equivalent tightening torque

must be calculated when using washers.

Rexroths consent is required if fi xing is

diff erent from above.

Installation point: fl atness of the mounting

surface 0.5

The wiring harness should be mechanically

fi xed in the area in which the control unit is

installed (spacing < 150 mm).

The wiring harness should be fi xated so that

in-phase excitation with the controller occurs

(e.g. at the controller mounting points).

If the mounting surface is not suffi ciently even, place fl exible compensating elements (e.g. rub-ber washers) between the fi xing points of the BODAS controller and the mounting surface.

Space required for mating connector

Space required for plugging and

unplugging the mating connector

Bosch Rexroth AG, RE 95204/07.2015

18 RC | BODAS Controller Installation position

Installation position

Note:Installation position only permissible with specifi ed angular range.

90

90

360

RE 95204/07.2015, Bosch Rexroth AG

BODAS Controller | RC Mating connector

19

Mating connector

Order designations for the connector set with the Rexroth material number R902603622

Bosch part numbers of the individual parts

Designation Number Module 58-pin Module 96-pin

Contact carrier code: A 1 per connector 1 928 404 780 1 928 404 781

Cover pre-installed 1 per connector 1 928 404 774 1 928 404 773

Secondary lock 1.2 1 per connector 1 928 404 760 1 928 404 762

Secondary lock 2.8 1 1 928 404 761

Wire tie (cable tie) 1 per connector 1 928 401 713

ContactsBDK 2.8 contactSurface: SNInsulation cross section: 2.2 to 3.0 mmLine cross section: 1.5 to 2.5 mm

6 (8)*) 1 928 498 057

Matrix 1.2 contactSurface: SNInsulation cross section: 1.2 to 1.6 mmLine cross section: 0.35 to 0.5 mm

52 (55)*) 1 928 498 137

Matrix 1.2 contactSurface: SNInsulation cross section: 1.2 to 1.6 mmLine cross section: 0.35 to 0.5 mm

96 (100)*) 1 928 498 137

Individual sealingWhite for BDK 2.8Cross section: 2.2 to 3.0 mm

6 (8)*) 1 928 300 600

*) The number in the brackets indicates how many contacts or individ-ual seals are included in the Rexroth connector set. The number with-out brackets indicates the requirement.

View of connector strip

Connector section 1Pins 101 to 196

Connector section 2Pins 201 to 258

The control unit connector strip can be ordered separately under Rexroth material number R917009804, e.g., for testing a wiring harness. Delivery only in quantities for lab use.

Bosch Rexroth AG, RE 95204/07.2015

20 RC | BODAS Controller Mating connector

Notes regarding assemblyPlease observe the assembly instructions for connectors (1 928 A00 48M) as well as the processing specifi cations for BDK 2.8 contacts (1 928 F00 025) and Matrix 1.2 con-tacts (1 928 A00 47M) when assembling the connectors. These assembly instructions are available from Bosch Rexroth upon request.

Note Please observe the following when assembling the connector in the vehicle: The wiring harness must be attached 150 mm from the outgoing wires and at the same vibration level as the control unit.

Recommended linesRecommended connecting lines for contacts 201 to 206:

Cross section 1.5 mm to 2.5 mm (16 to 14 AWG, 14 AWG with thin electric insulation)

Outer diameter: 2.2 mm to 3.0 mm

Recommended connecting lines for contacts 101-105, 124, 125-129, 148, 149-153, 172, 173-177, 196, 207, 220, 233, 246:

Cross section 1.0 mm to 1.5 mm (18 to 16 AWG) Outer diameter: 1.9 to 2.1 mm for 1.0 mm, 2.2 to

2.4 mm for 1.5 mm Lines with a cross section of 0.35 mm to 0.5 mm can also be used for these contacts (see other contacts below). However, the 1.0 mm to 1.5 mm cross sections can make it easier to insert the contacts into the connector.

Recommended connection lines for the contacts not men-tioned above:

Cross section: 0.35 mm to 0.5 mm (22 AWG) Outer diameter: 1.2 to 1.6 mm

Required toolsBosch part numbers for tools1)

Designation Type FLK-R line cross sections

BDK 2.8 contacts Matrix 1.2 contacts

1.5 to 2.5 mm2 0.35 to 0.5 mm2 1.0 mm2 1.5 mm2

Contact 1 928 498 057 1 928 498 137 1 928 498 138 1 928 498 139

Crimping tool with matrix 1 928 498 162 1 928 498 212 1 928 498 213 1 928 498 214

Quick-change tool 1 928 498 164 1 928 498 200 1 928 498 201 1 928 498 202

Wear parts set 1 928 498 166 1 928 498 206 1 928 498 207 1 928 498 208

Disassembly extraction tool 1 928 498 167 1 928 498 218

10 replacement needles for the extraction tool 1 928 498 168 1 928 498 219

Drawings and further information about Bosch connectors and tools can be found on the internet: www.bosch-connectors.com

1) Tools can be ordered from Bosch retailers or Bosch Service (www.bosch-service.com).

RE 95204/07.2015, Bosch Rexroth AG

BODAS Controller | RC Safety information

21

Safety information

General Reliable operation cannot be guaranteed if samples or

prototypes are used in series production machines. The proposed circuits do not imply any technical liability

for the system on the part of Bosch Rexroth. Incorrect connections could cause unexpected signals at

the outputs of the control unit. Incorrect programming or parameter settings on the

control unit may create potential dangers while the machine is in operation. It is the responsibility of the machine manufacturer to identify hazards of this type in a hazard analysis and to bring them to the attention of the end user. Rexroth assumes no liability for dangers of this type.

The component fi rmware/software must be installed or changed by Bosch Rexroth or by the authorized partner concerned in order to uphold the warranty.

It is not permissible to open the control unit or to mod-ify or repair the control unit. Modifi cations or repairs to the wiring could result in dangerous malfunctions.Repairs to the control unit may only be performed by Bosch Rexroth or by an authorized partner.

To switch off the system in emergencies, the stop switch (two-channel stop function) or the optional de-energize switch may be used. The switch must be in an easily accessible position for the operator. The system must be designed in such a way that safe braking is ensured when the outputs are switched off .

Make sure no pins are connected to a voltage source when the electronics is not powered. Thus, when the current supply is switched off , the supply for the elec-tronics, the output stages and the external sensor sup-ply have to be switched off together.

Make sure that the control units confi guration does not lead to safety-critical malfunctions of the complete system in the event of failure or malfunction. Such system behavior could result in death or serious prop-erty damage.

System developments, installation and commissioning of electronic systems for controlling hydraulic drives must only be carried out by trained and experienced special-ists who are suffi ciently familiar with the components used and with the complete system.

The machine may cause unforeseen hazards during con-trol unit commissioning and maintenance (with BODAS Tools). Before commissioning the system, you must therefore ensure that the vehicle and the hydraulic sys-tem are in a safe condition.

Make sure that nobody is in the machines danger zone. No defective or incorrectly functioning components may

be used. If the components should fail or demonstrate faulty operation, repairs must be performed immediately.

Controllers used to develop software may only be installed in series production machines if it can be guaranteed that these control units have not been fl ash-programmed with new software more than 500 times. Controllers that have been programmed more than 1000 are not to be installed in series production machines.

Notes on the installation point and position Do not install the control unit close to parts that gener-

ate considerable heat (e.g. exhaust). Radio transmitting equipment and mobile telephones

must not be used in the driver's cab without a suitable antenna or near the control electronics.

A suffi ciently large distance to radio transmitting sys-tems must be maintained.

All connectors must be unplugged from the electronics during electrical welding and painting operations.

Cables/wires must be sealed individually to prevent water from entering the device.

The control unit must not be electrostatically charged, e.g. during painting operations.

The control unit will heat up beyond normal ambient temperature during operation. To avoid danger caused by high temperatures, it should be protected against contact.

Install the control unit in such a way that the electrical plug is not facing upwards. This ensures that any con-densation water that may form can fl ow out.

Standing and permanently running water are not permit-ted anywhere near the circumferential groove (lid/base connector) or the pressure balance element (DAE).

The case must be wired to vehicle ground in order to comply with EMC guidelines. Metallic screws are used to create a connection to vehicle ground.

Bosch Rexroth AG, RE 95204/07.2015

22 RC | BODAS Controller Safety information

Notes on transport and storage If it is dropped, the control unit must not be used any

longer as invisible damage could have a negative impact on reliability.

Store control units at an average relative humidity of 60% and at a temperature between -10 C and 30 C. Storage temperatures between -20C and +40C are briefl y permissible, for up to 100 hours.

After a storage time of more than 5 years, the control unit must be examined by the manufacturer.

Notes on wiring and circuitry The electronics and the power outputs of a controller

must be fed from the same power source. When wiring the output stages, the maximum cumulative

output current for each output stage group should be noted. The cumulative output current means a perma-nent, simultaneous actuation of the output stages.

Lines to the speed sensors are to be shielded and kept as short as possible. The shield must be connected to the electronics on one side or to the machine or vehicle ground via a low-resistance connection.

The product may only be wired when it is de-energized. Lines to the electronics must not be routed close to

other power-conducting lines in the machine or vehicle. The wiring harness should be fi xed mechanically in the

area in which the control unit is installed (spacing < 150mm). The wiring harness should be fi xed so that in-phase excitation with the control unit occurs (e.g. at the control unit bolting point).

If possible, lines should be routed in the vehicle interior. If the lines are routed outside the vehicle, make sure that they are securely fi xed.

Lines must not be kinked or twisted, must not rub against edges and must not be routed through sharp-edged ducts without protection.

Lines are to be routed with suffi cient spacing to hot or moving vehicle parts.

PWM outputs must not be linked or bridged. PMW outputs (OUT_1 to OUT_18 and OUT_37 to

OUT_46) must not be used to power lamps. The sensor supplies can be pulled up by external

connection, e.g. the application of a higher voltage, because they operate only as a voltage source but not as a voltage sink! Pulling up a sensor supply may result in unexpected malfunctions and damage the control unit in continuous operation.

The high side outputs may not be externally connected to battery.

If the stop function is used in an application, contact 228 (INH) of the control unit must be connected to the stop switch in the vehicle. For a dual channel switch off function the contact SW-INH has to be connected to the stop switch too. Refer to the connection diagram.

Notes on proportional and switching solenoids and other wired inductive consumers

The proportional solenoids must not be wired with free-wheeling diodes.

Switching solenoids at control unit outputs do not need to be connected to free-wheeling diodes.

The electronics may only be tested with the proportional solenoids connected.

Other inductive loads that are in the system but not connected to the control unit must be connected to free-wheeling diodes. This also applies to relays (e.g. for shutting off the control unit) that are powered by the same source as the control unit.

Intended use The control unit is designed for use in mobile working

machines provided no limitations / restrictions are made to certain application areas in this data sheet.

Operation of the control unit must generally occur within the operating ranges specifi ed and released in this data sheet, particularly with regard to voltage, current, temperature, vibration, shock and other described environmental infl uences.

Use outside of the specifi ed and released boundary conditions may result in hazard to persons and/or cause damage to components which could result in subse-quential damage to the mobile working machine.

RE 95204/07.2015, Bosch Rexroth AG

BODAS Controller | RC Safety information

23RE | BODAS Controller

Improper use Any use of the control unit other than as described

under Intended use is considered to be improper. Use in explosive areas is not permissible. Damage resulting from improper use and/or from unau-

thorized interference in the component not described in this data sheet render all warranty and liability claims void with respect to the manufacturer.

Use in functions relevant to safety The customer is responsible for performing risk analysis

on the mobile working machine and determining the possible safety-related functions.

In safety-related applications, the customer is responsible for taking suitable measures to ensure safety (sensor redundancy, plausibility check, emergency switch, etc.). For example, a suitable assignment of input variables

(e.g., by connecting the acceleration pedal signal to two independent analog inputs) can be used to detect faults and to trigger specially programmed reactions.

Special measures may be taken if the plausibility check shows deviations between the setpoint values and the values read back from the microcontroller.

Product data that is necessary to assess the safety of the machine can be provided upon request or are listed in this data sheet. For all control units, the notes found in the API

description, in the online help section of BODAS design and in the safety-relevant project planning instructions must be observed.

The service life of the control unit may be reduced depending on the conditions in which it is used. See the safety-relevant project planning instructions for more information.

Safety features in the BODAS controller The input circuits for speed and analog signals partially

feature circuits that are mutually electrically isolated. Through appropriate input connections, the microcon-troller and, when used, the software diagnostic function can detect faults.

Faults in the voltage supply are detected by internal monitoring.

All output signals can be monitored by the microcon-troller with the appropriate software.

For service purposes, the control units can be operated with all power outputs de-energized.

The internal watchdog module centrally switches off the power supply of all proportional and switched outputs when there are malfunctions in the program run.

Further information In addition, the application-specifi c documents

(connection diagrams, software descriptions, etc.) are to be observed.

More detailed information on BODAS controllers may be found at www.boschrexroth.com/mobile-electronics

24

Bosch Rexroth AG, RE 95204/07.2015

Bosch Rexroth AGMobile ApplicationsGlockeraustrae 489275 Elchingen, GermanyyTel. +49 93 52 40 50 [email protected]

This document, as well as the data, specifi cations and other information set forth in it, are the exclusive property of Bosch Rexroth AG. It may not be reproduced or given to third parties without its consent. The data specifi ed above only serve to describe the product. No statements concerning a certain condition or suitability for a certain application can be derived from our information. The information given does not release the user from the obligation of own judgment and verifi cation. It must be remembered that our products are subject to a natural process of wear and aging.

RC | BODAS Controller

Ordering codeOptional accessoriesDescriptionBlock circuit diagramTechnical dataConnection diagramConnection variantsOverview of functionsDimensionsInstallation positionMating connectorSafety information

/ColorImageDict > /JPEG2000ColorACSImageDict > /JPEG2000ColorImageDict > /AntiAliasGrayImages false /CropGrayImages false /GrayImageMinResolution 150 /GrayImageMinResolutionPolicy /OK /DownsampleGrayImages true /GrayImageDownsampleType /Bicubic /GrayImageResolution 150 /GrayImageDepth -1 /GrayImageMinDownsampleDepth 2 /GrayImageDownsampleThreshold 1.50000 /EncodeGrayImages true /GrayImageFilter /DCTEncode /AutoFilterGrayImages true /GrayImageAutoFilterStrategy /JPEG /GrayACSImageDict > /GrayImageDict > /JPEG2000GrayACSImageDict > /JPEG2000GrayImageDict > /AntiAliasMonoImages false /CropMonoImages false /MonoImageMinResolution 300 /MonoImageMinResolutionPolicy /OK /DownsampleMonoImages true /MonoImageDownsampleType /Bicubic /MonoImageResolution 300 /MonoImageDepth -1 /MonoImageDownsampleThreshold 1.50000 /EncodeMonoImages true /MonoImageFilter /CCITTFaxEncode /MonoImageDict > /AllowPSXObjects false /CheckCompliance [ /None ] /PDFX1aCheck false /PDFX3Check false /PDFXCompliantPDFOnly false /PDFXNoTrimBoxError true /PDFXTrimBoxToMediaBoxOffset [ 0.00000 0.00000 0.00000 0.00000 ] /PDFXSetBleedBoxToMediaBox true /PDFXBleedBoxToTrimBoxOffset [ 0.00000 0.00000 0.00000 0.00000 ] /PDFXOutputIntentProfile (Coated FOGRA27 \050ISO 12647-2:2004\051) /PDFXOutputConditionIdentifier (FOGRA27) /PDFXOutputCondition () /PDFXRegistryName (http://www.color.org) /PDFXTrapped /False

/CreateJDFFile false /Description > /Namespace [ (Adobe) (Common) (1.0) ] /OtherNamespaces [ > > /FormElements true /GenerateStructure false /IncludeBookmarks true /IncludeHyperlinks true /IncludeInteractive false /IncludeLayers false /IncludeProfiles false /MarksOffset 6 /MarksWeight 0.250000 /MultimediaHandling /UseObjectSettings /Namespace [ (Adobe) (CreativeSuite) (2.0) ] /PDFXOutputIntentProfileSelector /UseName /PageMarksFile /RomanDefault /PreserveEditing true /UntaggedCMYKHandling /UseDocumentProfile /UntaggedRGBHandling /LeaveUntagged /UseDocumentBleed false >> ]>> setdistillerparams> setpagedevice

Click here to load reader

Reader Image
Embed Size (px)
Recommended